REMOTE CONTROLLED ELECTRICALLY OPERATED HYDRAULIC JACK COLLEGE NAME ABSTRACT A revolutionary change has taken place in the field of Fluid Power Technology due to the integration of electronics as a control medium for hydraulic components and systems. Due to sophistication of hydraulics and allied fields of power and higher accuracy in speed, force and position control. Efforts have been made to include the latest possible trends in the field of hydraulics and allied control areas to keep the ever changing state of the technology in hydraulics. Now a day more stress is given to LUXURY, COMFORT and SAFETY as much as possible with money and TECHNOLOGY available with the mankind. In that way to help those who are physically challenged this project is been made. That is a case of lifting a jack to an automobile, is troublesome to physically challenged human being. And we are using oil, hence the jack as a means of power transmissions. Hydraulic systems are now extensively used in almost all the engineering fields in varied applications. So we tried to grab the opportunity. Energy can neither be created nor be destroyed but it can be transformed from one form to another. The energy associated with human beings will decrease as he becomes older resulting unable to challenge physically. To overcome we have provided alternate source of energy by taking the power from wiper motor to drive the hydraulic jack loading subsequently and automatically, which substantially reduce the burden. Our project works on the mechanism of converting rotary motion of the wiper motor into reciprocating motion of the hydraulic jack plunger. A cylinder cage structure of wiper motor ensures maximum power delivered by consuming the available battery power which can be easily generated. Important thing is that the power is available at any instant and anyone can withdraw easily, without any hazard. Realizing that the engineers are more concerned with the applications than with theory, we have woven the subject-matter with this practical application in engineering and achieved the objective. Addition of number of figures, tables and examples is in proportionate to the addition of written word because they offer better visual appreciation and mental grasp.
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REMOTE CONTROLLED ELECTRICALLY OPERATED HYDRAULIC JACK
COLLEGE NAME
ABSTRACT
A revolutionary change has taken place in the field of Fluid Power Technology due to the
integration of electronics as a control medium for hydraulic components and systems. Due to
sophistication of hydraulics and allied fields of power and higher accuracy in speed, force
and position control. Efforts have been made to include the latest possible trends in the field
of hydraulics and allied control areas to keep the ever changing state of the technology in
hydraulics.
Now a day more stress is given to LUXURY, COMFORT and SAFETY as much as possible
with money and TECHNOLOGY available with the mankind. In that way to help those who
are physically challenged this project is been made. That is a case of lifting a jack to an
automobile, is troublesome to physically challenged human being. And we are using oil,
hence the jack as a means of power transmissions. Hydraulic systems are now extensively
used in almost all the engineering fields in varied applications. So we tried to grab the
opportunity.
Energy can neither be created nor be destroyed but it can be transformed from one form to
another. The energy associated with human beings will decrease as he becomes older
resulting unable to challenge physically. To overcome we have provided alternate source of
energy by taking the power from wiper motor to drive the hydraulic jack loading
subsequently and automatically, which substantially reduce the burden.
Our project works on the mechanism of converting rotary motion of the wiper motor into
reciprocating motion of the hydraulic jack plunger. A cylinder cage structure of wiper motor
ensures maximum power delivered by consuming the available battery power which can be
easily generated. Important thing is that the power is available at any instant and anyone can
withdraw easily, without any hazard.
Realizing that the engineers are more concerned with the applications than with theory, we
have woven the subject-matter with this practical application in engineering and achieved the
objective. Addition of number of figures, tables and examples is in proportionate to the
addition of written word because they offer better visual appreciation and mental grasp.
REMOTE CONTROLLED ELECTRICALLY OPERATED HYDRAULIC JACK
REMOTE CONTROLLED ELECTRICALLY OPERATED HYDRAULIC JACK
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POWERING THE MOTOR
Voltage
The standard voltage requirement for the wiper motor is 12 volts DC. The electrical system in a running automobile usually puts out between 13 and 13.5 volts, so it's safe to say the motor can handle up to 13.5 volts with no problem.
Current
The minimum required current for the motor is 1.6 amps at 70 rpm, 0.9 amps at 41 rpm (and 4 amps if you elect to run it at 106 rpm see note on the next page). These current ratings are for the motor spinning with no load. As you add mechanical load, these numbers can increase dramatically, doubling or even tripling under a heavy load. (When testing for torque, I found the motor to draw close to 14 amps in a stalled condition.) This factor must be taken into account when selecting a power supply. Since the motor will only use what it needs when it comes to current, it's best to provide a source with a higher current rating than you think you might need.
WIPER MOTOR DESIGN
Windshield wipers are designed and made to clear water from a windshield. The wiper parts
visible from outside the car are the rubber blade, the wiper arm holding the blade, a spring
linkage, and parts of the wiper pivots. The wiper itself has up to six parts called pressure
points or claws that are small arms under the wiper. Although the rubber is the familiar part
of the blade, the blade actually includes a metal strip called a blade frame with a slot along
the length of the frame and replacement holes in the frame. A wiper and pivot are mounted on
brackets at both ends of a long rod called the connecting link, and, as the force from the
motor push.
Wiper motor is a combination of 2 mechanical technologies to perform their tasks,
A combination electric motor and worm gear reduction provides power to the wipers
A neat linkage converts the rotational output of the motor into the back and forth
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The wipers combine two mechanical technologies to perform their task:
A combination electric motor and worm gear reduction provides power to the wipers.
A neat linkage converts the rotational output of the motor into the back-and-forth motion of the wipers.
LINKAGE
A short cam is attached to the output shaft of the gear reduction. This cam spins around as the wiper motor turns. The cam is connected to a long rod; as the cam spins, it moves the rod back and forth. The long rod is connected to a short rod that actuates the wiper blade on the driver's side. Another long rod transmits the force from the driver-side to the passenger-side wiper blade.
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INTRODUCTION TO HOW POWER DOOR LOCKS WORK
Between the keypads, keyless entry systems and conventional locks, some cars today have
four or five different ways to unlock the doors. How do cars keep track of all those different
methods, and what exactly happens when the doors unlock?
The mechanism that unlocks your car doors is actually quite interesting. It has to be very
reliable because it is going to unlock your doors tens of thousands of times over the life of
your car.
LOCKING AND UNLOCKING
Here are some of the ways that you can
unlock car doors:
With a key By pressing the unlock button inside
the car By using the combination lock on the
outside of the door By pulling up the knob on the inside
of the door With a keyless-entry remote control By a signal from a control center
In some cars that have power door locks, the lock/unlock switch actually sends power to the actuators that unlock the door. But in more complicated systems that have several ways to lock and unlock the doors, the body controller decides when to do the unlocking.
The body controller is a computer in your car. It takes care of a lot of the little things that make your car friendlier -- for instance, it makes sure the interior lights stay on until you start the car, and it beeps at you if you leave your headlights on or leave the keys in the ignition.
In the case of power door locks, the body controller monitors all of the possible sources of an "unlock" or "lock" signal. It monitors a door-mounted touchpad and unlocks the doors when the correct code is entered. It monitors a radio frequency and unlocks the doors when it receives the correct digital code from the radio transmitter in your key fob, and also monitors the switches inside the car. When it receives a signal from any of these sources, it provides power to the actuator that unlocks or locks the doors.
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INFRA-RED LIGHT
Infra-Red actually is normal light with a particular colour. We humans can't see this colour
because its wave length of 950nm is below the visible spectrum. That's one of the reasons
why IR is chosen for remote control purposes, we want to use it but we're not interested in
seeing it. Another reason is because IR LEDs are quite easy to make, and therefore can be
very cheap.
Although we humans can't see the Infra-Red
light emitted from a remote control doesn't
mean we can't make it visible.
A video camera or digital photo camera can
"see" the Infra-Red light as you can see in this
picture. If you own a web cam you're in luck,
point your remote to it, press any button and
you'll see the LED flicker.
Unfortunately for us there are many more sources of Infra-Red light. The sun is the brightest
source of all, but there are many others, like: light bulbs, candles, central heating system, and
even our body radiate Infra-Red light. In fact everything that radiates heat also radiates Infra-
Red light.
Therefore we have to take some precautions to guarantee that our IR message gets across to
the receiver without errors.
MODULATION
Modulation is the answer to make our signal stand out above the noise. With modulation we
make the IR light source blink in a particular frequency. The IR receiver will be tuned to that
frequency, so it can ignore everything else.
You can think of this blinking as attracting the receiver's attention. We humans also notice
the blinking of yellow lights at construction sites instantly, even in bright daylight.
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In the picture above you can see a modulated signal driving the IR LED of the transmitter on
the left side. The detected signal is coming out of the receiver at the other side.
In serial communication we usually speak of 'marks' and 'spaces'. The 'space' is the default
signal, which is the off state in the transmitter case. No light is emitted during the 'space'
state. During the 'mark' state of the signal the IR light is pulsed on and off at a particular
frequency. Frequencies between 30 kHz and 60 kHz are commonly used in consumer
electronics.
At the receiver side a 'space' is represented by a high level of the receiver's output. A 'mark' is
then automatically represented by a low level.
Please note that the 'marks' and 'spaces' are not the 1-s and 0-s we want to transmit. The real
relationship between the 'marks' and 'spaces' and the 1-s and 0-s depends on the protocol
that's being used. More information about that can be found on the pages that describe the
protocols.
THE TRANSMITTER
The transmitter usually is a battery powered handset. It should consume as little power as
possible, and the IR signal should also be as strong as possible to achieve an acceptable
control distance. Preferably it should be shock proof as well.
Many chips are designed to be used as IR transmitters. The older chips were dedicated to
only one of the many protocols that were invented. Nowadays very low power
microcontrollers are used in IR transmitters for the simple reason that they are more flexible
in their use. When no button is pressed they are in a very low power sleep mode, in which
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hardly any current is consumed. The processor wakes up to transmit the appropriate IR
command only when a key is pressed.
Quartz crystals are seldom used in such handsets. They are very fragile and tend to break
easily when the handset is dropped. Ceramic resonators are much more suitable here, because
they can withstand larger physical shocks. The fact that they are a little less accurate is not
important.
The current through the LED (or LEDs) can vary from 100mA to well over 1A! In order to
get an acceptable control distance the LED currents have to be as high as possible. A trade-
off should be made between LED parameters, battery lifetime and maximum control distance.
LED currents can be that high because the pulses driving the LEDs are very short. Average
power dissipation of the LED should not exceed the maximum value though. You should also
see to it that the maximum peek current for the LED is not exceeded. All these parameters
can be found in the LED's data sheet.
A simple transistor circuit can be used to drive the LED. A transistor
with a suitable HFE and switching speed should be selected for this
purpose.
The resistor values can simply be calculated using Ohm's law.
Remember that the nominal voltage drop over an IR LED is
approximately 1.1V.
The normal driver, described above, has one disadvantage. As the battery
voltage drops, the current through the LED will decrease as well. This
will result in a shorter control distance that can be covered.
An emitter follower circuit can avoid this. The 2 diodes in series will
limit the pulses on the base of the transistor to 1.2V. The base-emitter
voltage of the transistor subtracts 0.6V from that, resulting in a constant amplitude of 0.6V at
the emitter. This constant amplitude across a constant resistor results in current pulses of a
constant magnitude. Calculating the current through the LED is simply applying Ohm's law
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again.
THE RECEIVER
Many different receiver circuits exist on the market. The most important selection criteria are
the modulation frequency used and the availability in you region.
In the picture above you can see a typical block diagram of such an IR receiver. Don't be
alarmed if you don't understand this part of the description, for everything is built into one
single electronic component.
The received IR signal is picked up by the IR detection diode on the left side of the diagram.
This signal is amplified and limited by the first 2 stages. The limiter acts as an AGC circuit to
get a constant pulse level, regardless of the distance to the handset.
As you can see only the AC signal is sent to the Band Pass Filter. The Band Pass Filter is
tuned to the modulation frequency of the handset unit. Common frequencies range from 30
kHz to 60 kHz in consumer electronics.
The next stages are a detector, integrator and comparator. The purpose of these three blocks
is to detect the presence of the modulation frequency. If this modulation frequency is present
the output of the comparator will be pulled low.
As I said before, all these blocks are integrated into a single
electronic component. There are many different manufacturers of
these components on the market. And most devices are available
in several versions each of which are tuned to a particular
modulation frequency.
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Please note that the amplifier is set to a very high gain. Therefore the system tends to start
oscillating very easily. Placing a large capacitor of at least 22µF close to the receiver's power
connections is mandatory to decouple the power lines. Some data sheets recommend a
resistor of 330 Ohms in series with the power supply to further decouple the power supply
from the rest of the circuit.
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WORKING OF REMOTE CONTROLLED
ELECTRICALLY OPERATED HYDRAULIC
JACK
Place the project model under the chassis at the pre-specified jacking points. Is then
connected to the power source i.e. battery. The whole assembly is operated by a
remote device.
The standard voltage requirement for the wiper motor is 12 volts DC and is supplied
to the wiper motor, by means of a battery available in the automobile. Since the
motor will only use what it needs, so no need to bother of battery getting weaker with
this operation.
Upon pressing the remote button, the current passing through the wiper motor
resulting in the rotation of output linkage
A neat linkage converts the rotational output of the motor into the back and forth
motion of the wipers and hence the hydraulic jack plunger is moved up and down
where the pumping unit is a single plunger type.
The force acting on the plunger causes a circular pipe to transmit the hydraulic liquid
from the smaller cylinder to the larger cylinder, with a check valve to prevent
backflow. The larger cylinder lifts a load. The load is indicated on piston of hydraulic
jack with rise in its mean level.
After attaining a required lift, using remote further lifting can be stopped and the
tyre changing or any other operation can be carried out. Once the work is over, by
remote controller the jack can be lowered by pressure release valve.
A pressure release valve is provided on the pumping unit. Which is automatically
operated by a the central lock actuator
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METHOD OF JACKING AND JACKING
POINTS
If you are using the jack that came with the car, it should be designed to fix securely onto specific points under the car, typically here ;
There will be a cut out or indentation behind the front wheel and infront of the back wheel that will accept the head of the jack. When the head of the jack is located at the correct points, it should not move about whilst you are operating it and raising/lowering the car.
How do I do it safely then? For the purpose of this exercise we will assume that you are changing a wheel on your car.
If you are performing something else under your car, just stick to the stuff relevant to chocking the wheels, raising the car and securing it.
Step 1. MOST IMORTANT - find a flat and solid surface to jack up your car. Don't jack up any car when it is not on level ground or has an uneven surface.
This is just asking for trouble and you could end up in hospital or worse.
Step 2. Make sure that the handbrake is fully on and the car is in gear.
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Step 3. Secure the wheel on the opposite corner to the one you are removing, example if you are changing the wheel on the front passenger side (nearside), then you should secure the rear drivers side (offside) wheel. The wheel should be 'chocked' so as to help prevent the car from rolling when we lift it with the jack.
I have chocked wheels with house bricks or pieces of wood in the past, but the most secure and safe method I found was proper 'wheel chocks' (see picture below).
They were very inexpensive to buy and are far safer than using anything else and the can potentially be a life saver so why cut corners;
Wheel chocks
Step 4. Put the jack into its jacking position and take the weight if the car slightly. DO NOT LIFT THE WHEEL OFF THE FLOOR. If you are using the manufacturers jack then it will be easy to locate the correct jacking position. If you are using a trolley, bottle or scissor jack you will need to find a strong and secure place under the car to position it.
Example of secure position for jacking when using trolley jack
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Here are a couple more examples of jacking points, your owners manual or Haynes
Manual may help you identify safe jacking points also.
Step 5. The reason for not lifting the wheel fully off the floor is so that we can loosen the wheel nuts slightly and with it on the ground the wheel won't spin around. If you were to jack up the car fully and then try and loosen the wheel nuts, the wheel will most likely just keep turning around.
So with the weight of the car on the jack, take your wheel bolt spanner (or wheel brace/spider as shown below) and loosen off all the bolts very slightly.
Step 6. Now raise the car slowly with the jack until the tyre is off the floor.
Step 7. At this point you can now fully remove all of the wheel bolts and put the safely to one side. Now you can remove the wheel by just lifting it off the car, mind your back as large wheels/tyres can be heavy. Place the removed wheel under the car as a back-up to the jack.
NOTE - if the wheel is stiff and does not want to come off, put one hand on the top (6 o'clock) and one at the bottom (12 o'clock) and try to rock it loose. It should not require too much force/effort to get the wheel loose but take care not to rock the car off its jack.
Step 8. Now you can fit your replacement wheel, making sure that the bolt holes on the wheel are lined up with the holes on the car wheel hub.
Line up the holes and refit the bolts you removed earlier.
With the car jacked up, tighten each bolt as much as you can until the wheel starts to turn. Now to ensure that the wheel goes on straight, make sure that when you tighten the bolts, they are tightened up as follows;
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4 stud (bolt) wheels
5 stud (bolt) wheels
Step 9. Lower the car to the floor with the jack and remove it. Now perform the final tightening of the wheel bolts using the same sequence as shown above.
Step 10. Remove all tools and equipment to you has used and stores them away safely.
Warning! The car must be on a hard, stable, level surface! Not in the dirt, not in the gravel, and maybe even not on asphalt.
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SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
1. Regularly inspect and lubricate jack to ensure it in good working order and condition.
Does not use the jack if damaged or a fault is suspected-check section 5 troubles
shooting. If necessary, immediately repair or replace damaged parts.
2. Use recommended parts only; the use of unauthorized parts may be dangerous and
will invalidate your warranty.
3. Use jack on level and solid ground, preferably concrete.
4. Park the vehicle and apply hand brake. Switch off the engine and place chokes under
the wheels.
5. Ensure a minimum distance of 0.5 m between vehicle and static objects such ass
doors, walls, etc. to allow for tilting during jacking.
6. Ensure all persons are out of the vehicle before jacking. Do not enter vehicle whilst it
is supported on the jack or axle stands.
7. Check lifting point is centered and stable on jack saddle. Positions jack so as to avoid,
operating it from under vehicle.
8. Keep hands etc. clear of moving parts during raising and lowering of the vehicle.
9. Road side wheel changing is hazardous. Use hazard warning lights.
10. When changing a wheel, slightly loosen wheel nuts/bolts prior to jacking vehicle.
Screw wheel nuts/bolts back before lowering vehicle. Finally tighten when vehicle is
fully lowered.
11. DO NOT exceed the rated capacity of the jack and do not operate the jack beyond its
maximum pump stroke.
12. DO NOT try to move the vehicle, or try to start the engine, when the vehicle is jacked
up.
13. DO NOT jack a vehicle if it may result in the spillage of fuel, battery acid, or other
dangerous substances.
14. Do not place any part of your body under vehicle whilst it is supported by the jack.
15. DO NOT use jack to support extensions or cradles.
16. DO NOT top up jack with brake fluid. Use hydraulic oil only. Do not adjust the safety
overload valve.
REMOTE CONTROLLED ELECTRICALLY OPERATED HYDRAULIC JACK
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OPERATING INSTRUCTIONS
1. Check that the ground upon which the jack will stand is level and solid.
2. Position the jack saddle under the vehicle manufacturers recommended lifting point.
3. Using the screw extension necessary raise the saddle to the lifting point.
4. Pump the unit until the required height is achieved.
5. Ensure that the suitable axle’s stands are provided and removed after and before
jacking. The lowering speed is controlled by the amount of release valve is opened.
Turn anti-clockwise and lower slowly and carefully.
MAINTENANCE
1. When the jack is not in use, piston must be in their lowest positions to minimize
corrosion.
2. Keep the jack clean and lubricate all moving parts with acid free oil on a regular
basis.
3. To check oil level, fully lower the jack. Remove the filler plug. The correct oil level is
to the bottom of the filler plug opening.
4. After a year of extensive use, the oil should be replaced.
5. To replace the oil fill as required. Pump (unloaded jack) 5 or 6 times to expel air.
Pump jack to full height and pour off excess oil before refitting plug.
6. Periodically check the pump piston and piston rod for signs of corrosion. Clean
exposed areas with a clean oiled cloth.
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TROUBLE SHOOTING
PROBLEM POSSIBLE CAUSE REMEDY
Jack will not lift the load
Overloaded Be sure to use jack with adequate capacity
Oil level low Top up oil level
Release valve not correctly closed
Check and close release valve
Air in system
Open release valve and air vent and pump the jack, a few times. Close valve and retry
Packing worm or defective Return Jack to local service agent
Jack does not lift high enough or feels spongy
Oil level low Top up oil level
Worm seals Return Jack to local service agent
Air in system
Open release valve and air vent and pump
Release valve not closed the jack, a few times. Close valve and retry
Jack lifts but will not hold load
Release valve partially open Check and close release valve
Dirt on valve seats
Lower jack, close release valve. Pull up lifting arm to full height by hand. Open the release valve to lower arm.
Air in system
Open release valve and air vent and pump the jack, a few times. Close valve and retry
Faulty seals Return Jack to local service agent
Jack will not lower completely
Ram damaged Contact local service agent
Air in system
Open release valve and air vent and pump the jack, a few times. Close valve and retry
Release valve partially open Check and fully open release valve
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CALCULATION PART
CALCULATION PART
For example;
A hydraulic jack consists of a handle cum lever of 30 cm length and an assembly of
given dimensions. In order to that a load of 20 kN be supported by the jack, what
should be the force exerted on the handle? The distance between the fulcrum of
the lever and the point where the plunger is connected is 25 mm.
Area of cross section of the large piston = 𝛑𝐝²
𝟒 =
𝝅×(𝟎.𝟎𝟓)²
𝟒 =0.0196 m2
Pressure of the hydraulic fluid under the piston should be such as to balance the force
applied on the piston.
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P = 𝟐𝟎×𝟏𝟎𝟎𝟎
𝟎.𝟎𝟏𝟗𝟔 = 𝟏𝟎. 𝟏𝟖 × 𝟏𝟎𝟔 𝑵 𝒎²
By Pascal’s law of pressure is transmitted undiminished in all directions. The pressure at
the bottom of the small piston must be . 𝟏𝟖 × 𝟏𝟎𝟔 𝑵 𝒎² .
The force exerted on the small piston must be =(𝐏 × 𝛑𝐝²
𝟒) N
= 𝟏𝟎. 𝟏𝟖 × 𝟏𝟎𝟔 ×𝛑× 𝟎.𝟎𝟏𝟓 𝟐
𝟒
= 1800 N
The force desired to be exerted at the handle of lever should be F = 1800×𝟐𝟓
𝟑𝟎𝟎 = 150 N
TORQUE REQUIRED
T = Torque =? Nm
P = Power = 17 watt
N₁ = at low speed = 60 rpm
N₂ = at high speed = 120 rpm
CASE 1: CASE 2:
T = (P) ÷ (2ΠN₁) T = (P×60) ÷ (2ΠN₂)
T = (17×60) ÷ (2×Π×60) T = (17×60) ÷ (2×Π×120)
T = 2.78 Nm T = 1.35 Nm
The torque obtained will be maximum at the lower speeds. Hence the same is adopted.
Hydraulic Jack plunger actuation length = 28 mm
Linkage lengths given are;
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PHOTOGRAPHS
REMOTE CONTROLLED ELECTRICALLY OPERATED HYDRAULIC JACK
REMOTE CONTROLLED ELECTRICALLY OPERATED HYDRAULIC JACK
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Wiper motor and its dismantled view showing worm gear engaged with armature shaft
ARMATURE & MAGNETS ATTACHED TO A METALLIC CONTAINER TO CUT FLUX
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Central locking system and its transverse sectional view
INFRA RED REMOTE SENSOR GEAR REDUCTION
REMOTE CONTROLLED ELECTRICALLY OPERATED HYDRAULIC JACK